flame rollout on trane high efficiency furnace fails only on extremely cold nights.checked everything and everything is fine when i go there during the day furnace is 2 years old i noticed when i installed new switch that the whole in the ignition chamber that the switch goes in was a very tight fit can this cause premature heating of the switch and make it fail

make sure you replace parts with manufacturer exact replacement. the fit should not be a problem. i agree the flue and gas pressure should be checked. a rollokut switch opening with unknown cause is serious. if you cannot resolve it, you should get the manufacturer tech support rep involved.